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PAKISTAN ENGINEERING COUNCIL Curriculum for Engineering Practice
Examination (EPE)
(Chemical & Polymer Engineering)
Total Marks: 100
MAIN OBJECTIVE:
The main objective of Engineering Practice Examination (EPE) is
the assessment of competence, knowledge and skills of a Registered
Engineer (RE), after having attained a minimum of five years of
practical experience in relevant field of engineering from a
recognized engineering organization, institution or allied service,
and has earned requisite CPD (Continuing Professional Development)
credit points. PART-I (COMMON TO ALL DISCIPLINES)
This is common to all disciplines comprising of 30 questions of
one mark each (total marks 30) with the duration of 2 hours,
dealing with engineering related management, communication skills
and ethics. 1. MANAGEMENT (ENGINEERING RELATED) 34%
i. Quality Issues: fundamental concepts, application and
role
ii. Finance: cost analysis, financial discipline
iii. Procurement/Legal: bidding, contracts, arbitration,
guarantees, liabilities
iv. Latest Trends: emerging technologies and their
applications.
Suggested Books:
PEC bidding/contract documents (www.pec.org.pk;
www.picc.org.pk)
FIDIC documents
W.G. Sullivan, J.A. Bontandelli and E.M. Wicks, Engineering
Economy, 11th Ed., Prentice Hall Inc., 1999
Franklin and John Stermole, Economic Evaluation and Investment
Decision Methods (9th Edition)
Project Management Institute , A Guide to the Project Management
Body of Knowledge (PMBOK Guide) - Fourth Edition, Published by
Project Management Institute, weblink: A Guide to the Project
Management Body of Knowledge (PMBOK Guide) - Fourth Edition,
2008.
2. WRITTEN COMMUNICATION SKILLS 33%
i. English Language Communication Skills
Paragraph and essay writing
Academic and presentation skills
ii. Technical Report Writing Skills
Project/ research proposals
Monitoring and evaluation
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Progress and financial reporting
iii. Knowledge Management and Leadership Skills
Suggested Books:
Writing. Intermediate by Marie-Christine Boutin, Suzanne Brinand
and Francoise Grellet. Oxford Supplementary Skills. Fourth
Impression 1993. ISBN 0 19 435405 7 Pages 20-27 and 35-41
Hargie, O. (ed.) Handbbook of Communications Skills,
Routledge
Writing. Advanced by Ron White. Oxford Supplementary Skills.
Third Impression 1992, ISBN 0 19 435407 3
Practical English Grammar by A.J. Thomson and A.V. Martinet.
Exercises1, 3rd Ed., Oxford University Press, 1997. ISBN
0194313492
Ellen, K. 2002. Maximize Your Presentation Skills: How to Speak,
Look and Act on Your Way to the Top, Prima Lifestyles - 2005
Oxford English Dictionary or equivalent, (Latest Edition)
3. ETHICAL AND SOCIAL ISSUES 33%
i. Code of ethics
ii. Professional obligation of engineers
iii. Role of opportunity and conflict
iv. Interpersonal relations, social stratification and
culture
Suggested Books:
PEC Code of Ethics (http://pec.org.pk/code_ethics.aspx)
PEC Code of Conduct (http://pec.org.pk/code_conduct.aspx)
Ethics in Engineering, Martin M. W., Martin M. and R.
Schinzinger, McGraw-Hill, (Latest Edition)
Ethics in Engineering Practice and Research, Whitbeck C.,
Cambridge University Press, (Latest Edition)
Finchan, R., & Rhodes, P. (2003), Principles of
Organizational Behavior, 3rd Ed., Oxford.
Project Management Institute , A Guide to the Project Management
Body of Knowledge (PMBOK Guide) - Fourth Edition, Published by
Project Management Institute, weblink: A Guide to the Project
Management Body of Knowledge (PMBOK Guide) - Fourth Edition,
2008.
PART-II (BREADTH)
This part attempts to assess the breadth of Chemical
Engineering. The examination of this part would comprise 30
multiple choice questions (total 30 marks) for 2-hours duration. 1.
MATHEMATICS, PROBABILITY & STATISTICS 6%
i. Analytical geometry, integral calculus ii. Matrix operation
iii. Roots of equation iv. Vector and tensor analysis v.
Differential equation, differential calculus
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vi. Measurement of central tendencies and dispersions vii.
Probability distributions, conditional probabilities viii.
Estimation of regression and curve fitting ix. Testing of
hypothesis x. Laplace transform
Suggested Books:
Erwin Kreyszig, Advanced Engineering Mathematics, Ninth Edition,
2005, International Edition, John Wiley & Sons, ISBN:
0471728977.
Stephen Goode, Differential Equations and Linear Algebra, 2nd
Ed., 2000, Prentice Hall, ISBN: 013263757X.
Susan Milton and Jesse C Arnold, Introduction to Probability and
Statistics: Principles and Applications for Engineering and the
Computing Sciences, 4th Ed., 2003, McGraw-Hill, ISBN:
007246836.
2. Chemistry: 10%
i. Nomenclature ii. Oxidation & reduction iii. Periodic
table iv. States of matter v. Acids and bases vi. Equations,
equilibrium vii. Metals & nonmetals
Suggested Books:
R Gopalan et al, Engineering Chemistry, 1999.
David R. Klein General Chemistry as Second Language, 2005.
3. ENGINEERING MECHANICS: 6%
i. Statics
Resultants of force systems
Concurrent force systems
Equilibrium of rigid bodies
Frames & trusses
Centroid of area
Area moments of inertia
Friction
ii. Dynamics
Linear motion
Angular motion
Mass moment of inertia
Impulse & Momentum applied to particles & rigid
bodies
Work energy & power applied to particles & rigid
bodies
Friction. Suggested Books:
Hibler, R.C. Engineering Mechanics, 11th Ed, Prentice Hall,
2006
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Khurmi, R. S. Engineering Mechanics, 19th Ed, S. Chand, 1990
J. L. Meriam & L.G.Kraige, Engineering Mechanics 6th Ed.,
John Wiley & Sons
4. STRENGTH OF MATERIAL/MATERIAL PROPERTIES 6%
i. Fundamental Laws and principles of stress and strain ii.
Shear Force (SF), Bending Moment (BM), SF and BM diagrams iii.
Stress types iv. Strain caused by axial load, bending load, torsion
& shear v. Deformations vi. Plastic verses elastic deformations
vii. Combined stresses viii. Columns.
Suggested Books:
Pytel, A. & F.L.Singer, Strength of Materials, 4th Ed,
Harper & row Publishers, 1987.
G H Ryder, Strength of Materials, 3rd Ed., Macmillan, 1969. 5.
ELECTRICITY AND MAGNETISM 6%
i. Charge, energy, current, voltage, power ii. Work done in
moving a charge in an electric field, force between charges iii.
Current & voltage laws iv. Equivalent circuits v. Capacitance
& inductance vi. Reactance & impedance vii. Susceptance
& admittance viii. AC circuits ix. Basic complex algebra.
Suggested Books:
Halliday, Resnick, "Krane, Physics, Volume 2, 5th Ed.
Kittle C, Introduction to Solid State Physics, Willey New
York,2000
Stan Gibilisco, Applied Physics, McGraw-Hill, 2002, ISBN
0071382011 6 MATERIAL/ ENERGY BALANCES 8%
i. Mass balance
ii. Energy balance
iii. Control boundary concept
iv. Steady-state process
v. recycle process
vi. Bypass process
vii. Combustion.
Suggested Books:
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Himmelblau David M. Basic Principles and Calculations in
Chemical Engineering, 7th Ed. 2003, Prentice Hall PTR
Felder Richard M., Rousseau Ronald W., Elementary Principles of
Chemical Processes, 3rd Ed., 2001, John Willey & Sons.
Reklaitis G.V., Schneider Daniel R., Introduction to Material
and Energy Balances, 1983, John Wiley & Sons.
Hougen Olaf A., Watson Kenneth M., Chemical Processes
Principles, 2004, John Wiley and Sons & CBS Publishers.
Chopy & Hicks, Handbook of Chemical Engineering
Calculations, 2nd Ed., 1994, McGraw-Hill Professional
Publishing.
7. CHEMICAL ENGINEERING THERMODYNAMICS 6%
i. Thermodynamics Laws
ii. Properties and processes
iii. Properties and phase diagram
iv. Equation of state
v. Steam table
vi. phase equilibrium and phase change
vii. Chemical equilibrium
viii. Heats of reaction
ix. Cyclic processes and efficiency
x. Heats of mixing.
Suggested Books:
Smith J.M., Van Ness H.C., Abbott M.M., Chemical Engineering
Thermodynamics, 6th Ed., 2001, McGraw Hill International Ed.
Daubert Thomas E., Chemical Engineering Thermodynamics, 1st Ed.,
1985, McGraw Hill Book Company.
Sandler Stanley I., Chemical and Engineering Thermodynamics, 3rd
Ed., John Wiley and sons, Inc.
8. FLUID DYNAMICS 10%
i. Bernoulli equation and mechanical energy balance
ii. Hydrostatic pressure
iii. Dimensionless numbers
iv. Laminar and turbulent flow
v. Velocity head
vi. Friction losses
vii. Pipe networks
viii. Compressible and incompressible flow
ix. Flow measurement
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x. Pumps, turbines, and compressors
xi. Non-newtonian flow
xii. Flow through packed beds.
Suggested Books:
McCabe Warren L., Smith Julian C., Harriott peter, Unit
Operations of Chemical Engineering, 6th Ed., 2001, McGraw Hill,
Inc.
Coulson J.M., Richardson J.F., Chemical Engineering, Vol-I,
1985, The English Book Society and Pergamon Press.
Holland, F.A. & Bragg, R., Fluid flow for Chemical
Engineers, 2nd Ed., Butterworth & Heinemann, 1995.
White, F.M., Fluid Mechanics, 4th Ed., McGraw-Hill, 1999.
Noel Noel-de-Nevers, Fluid Mechanics for Chemical Engineers,
McGraw Hill.
9. HEAT TRANSFER 10%
i. Conductive & convective heat transfer
ii. Radiation heat transfer
iii. Heat transfer coefficients
iv. Heat exchanger types
v. Flow configuration
vi. LMTU & NTU
vii. Fouling
viii. Shell and tube heat exchanger design.
Suggested Books:
Kern Donald Q. Process Heat Transfer , 1997, McGraw Hill Book
Co.
James R. Welty, Charles E. Wicks, Robert E. Wilson, and Gregory
L. Rorrer , Heat, Mass and Momentum Transport, 5th Ed., 2008, John
Wiley & Sons,. Inc., ISBN: 978-0-470-12868-8
Cengel Yunus A. Heat Transfer-A Practical approach, 1988, McGraw
Hill, Book Company.
Incropera Frank P., De Witt David P., Fundamentals of Heat and
Mass Transfer 5th Ed., 2002, John Wiley and Sons.
Coulson J.M., Richardson J.F., Chemical Engineering Vol-I, 1999,
The English Book Society and Pergamon Press
Coulson J.M., Richardson J.F., Chemical Engineering Vol-II, 5th
Ed., 2002, The English Book Society and Pergamon Press
J.P. Holman, Heat Transfer, 2002, McGraw Hill Book Company.
10. MASS TRANSFER 10%
i. Diffusion ii. Mass transfer coefficient
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iii. Equilibrium stage method iv. Graphical method v.
differential method vi. Separation systems vii. Humidification and
drying.
Suggested Books:
James R. Welty, Charles E. Wicks, Robert E. Wilson, and Gregory
L. Rorrer , Heat, Mass and Momentum Transport, 5th Ed., 2008, John
Wiley & Sons,. Inc., ISBN: 978-0-470-12868-8
MeCabe Warren L., Smith Julian C., Harriott peter, Unit
Operations of Chemical Engineering, 7th Ed., 2005, McGraw Hill
Inc.
Coulson J.M., Richardson J.F., Chemical Engineering, Vol-II, 5th
Ed., 2002., The English Book Society and Pergamon Press.
Incropera Frank P., De Witt David P., Fundamentals of Heat and
Mass Transfer, 3rd Ed., 1990, John Wiley and Sons.
Schweitzer, Handbook of Separation Techniques for Chemical
Engineers, 1979, McGraw Hill Book Co.
Coulson J.M., Richardson J.F., Chemical Engineering, Vol-I,
1999. The English Book Society and Pergamon Press
11. COMPUTER APPLICATIONS IN CHEMICAL ENGINEERING 6%
i. Numerical methods and concepts
ii. Spread sheet for Chemical Engineering calculation
iii. Statistical data analysis.
Suggested Books:
Bruce A. Finlayson, Introduction to Chemical Engineering
Computing, 2006, John Wiley and Sons, Ltd.
Norton, Peter, Introduction to Computers, 5th Ed., 2010, Career
Publishing.
S.E. Lyshevski, Engineeirng and Scientific Calculation using
Matlab, 2003.
K.J. Beers, Numerical Methods for Chemical Engineering:
Application in MATLAB, 2007, Cambridge University Press.
12. PROCESS DYNAMICS AND CONTROL 9%
i. Sensors and control valves
ii. Dynamics
iii. Feed back and feed forward control
iv. PID controller concept
v. Cascade control
vi. Control loop design
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vii. Tuning PID controller and stability
viii. Open-loop and close-loop transfer functions.
Suggested Books:
Coughanor, D.R. and Koppel, C.B., Process system Analysis &
Control, 1991, McGraw Hill.
Peter Harriott Process Control, 1984, McGraw-Hill Inc., US,
ISBN: 0070993424.
G. Stephanupolos, Chemical Process Control, 2002, Prentice
Hall.
Austin E. Fribance, Handbook of Instrumentation.
13. TRANSPORT PHENOMENON 7%
i. Newtons Law, Fouriers Law and Ficks Law
ii. Generalization of basic Laws of diffusion
iii. Equations of continuity, motion, energy and continuity in
multi-component system
iv. Special forms of equations of motion, energy and
continuity
v. Mathematical representation of chemical engineering
systems
vi. specification of initial and boundary conditions
vii. Dimensional analysis
viii. Time average transport equations for turbulent flow
systems and turbulent transport properties
ix. Boundary layer approximations
x. Radiation heat transfer.
SUGGESTED BOOKS:
R. B. Bird et al, Transport Phenomena, 2nd Edition, 2002, John
Wiley & Sons, New York.
J. R. Welty et al, Fundamentals of Momentum, Heat and Mass
Transfer, 3rd Edition, 1984, John Wiley & Sons, New York.
R. S. Brodkey and H. C. Hershey, Transport Phenomena: A Unified
Approach, International Edition, 1988, McGraw Hill, New York.
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PART-III (DEPTH)
This part aims to assess the depth of Chemical Engineering. The
examination of this part would comprise 40 multiple choice
questions for 3-hours duration. PART-III-A (FOR ALL AREAS OF
PRACTICE)
This part comprises of 20 multiple choice questions for 1.5
hours and will be attempted by all the candidates. 1. HEAT TRANSFER
25%
i. Physical properties, conduction, free convective heat
transfer coefficient, forced convective heat transfer coefficient
(metallic and non metallic), phase change, combination of
mechanics, insulation, measurement instruments,
ii. Heat exchangers, over all heat transfer coefficient, fouling
factors, Reynolds numbers, LMTD, f-factor
iii. Heat exchanger types
iv. Heat exchanger design
v. Evaluation of existing and net exchanger systems
vi. Service use of heat transfer equipment, radiant and
convective transfer.
Suggested Books:
Kern Donald Q., Process Heat Transfer , 1997, McGraw Hill Book
Company.
James R. Welty, Charles E. Wicks, Robert E. Wilson, and Gregory
L. Rorrer , Heat, Mass and Momentum Transport, 5th Ed., 2008, John
Wiley & Sons,. Inc., ISBN: 978-0-470-12868-8
Cengel Yunus A. Heat Transfer-A Practical approach , 1988,
McGraw Hill, Book Company.
Incropera Frank P., De Witt David P., Fundamentals of Heat and
Mass Transfer, 5th Ed., 2002, John Wiley and Sons.
Coulson J.M., Richardson J.F., Chemical Engineering, Vol-I,
1999. The
English Book Society and Pergamon Press
Coulson J.M., Richardson J.F., Chemical Engineering, Vol-II, 5th
Ed., 2002, The English Book Society and Pergamon Press.
J.P. Holman, Heat Transfer, 2002, McGraw Hill Book Company. 2.
MASS TRANSFER 25%
i. Phase Equilibria
Equilibrium data (e.g. VLE, LLE): equations of state
Equilibrium data (e.g. VLE, LLE): Henry's Law and Raoult's
Law
Equilibrium data (e.g. VLE, LLE): non-ideal solutions
Equilibrium data (e.g., VLE, LLE): zoetrope systems
Phase equilibrium calculations: bubble and dew points
Phase equilibrium calculations: flash calculation
Diffusion (e.g., purification, water treatment, chip
manufacturing, chemical vapor deposition)
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ii. Mass Transfer Contactors: (Absorption, Stripping,
Distillation, Extraction)
Continuous contacting (packed): minimum rate of flow of liquid
(absorption), vapor (stripping), solvent (extraction) and reflux
(distillation)
Continuous contacting (packed): minimum number of transfer units
or stages
Continuous contacting (packed): height and number of transfer
units or stages
Continuous contacting (packed): types of packing
Continuous contacting (packed): flooding-calculation of minimum
vessel diameter
Continuous contacting (packed): feed location for distillation
column/tower
Trayed contactors: minimum rate of flow of liquid (absorption),
vapor (stripping), solvent (extraction), and reflux
(distillation)
Trayed contactors: minimum number of stages
Trayed contactors: theoretical stagesgraphical methods
Trayed contactors: floodingcalculation of minimum vessel
diameter
Trayed contactors: stage efficiency
Trayed contactors: feed location for distillation
column/tower
iii. Miscellaneous Separation Processes
Drying
Adsorption (e.g., PSA, water treatment)
Suggested Books:
James R. Welty, Charles E. Wicks, Robert E. Wilson, and Gregory
L. Rorrer , Heat, Mass and Momentum Transport, 5th Ed., 2008, John
Wiley & Sons,. Inc., ISBN: 978-0-470-12868-8
MeCabe Warren L., Smith Julian C., Harriott peter, Unit
Operations of Chemical Engineering, 7th Ed., 2005, McGraw Hill
Inc
Coulson J.M., Richardson J.F., Chemical Engineering, Vol-II, 5th
Ed., 2002, The English Book Society and Pergamon Press
Incropera Frank P., De Witt David P., Fundamentals of Heat and
Mass Transfer, 3rd Ed., 1990, John Wiley and Sons
Schweitzer, Handbook of Separation Techniques for Chemical
Engineers, 1979, McGraw Hill Book Co.
Coulson J.M., Richardson J.F., Chemical Engineering, Vol-I,
1999. The English Book Society and Pergamon Press.
3. CHEMICAL REACTION ENGINEERING 25%
i. Reaction rates and order ii. Rate constant iii. Conversion,
yield, and selectivity iv. Series and parallel reactions v. Forward
and reverse reactions vi. Energy/material balance around a reactor
vii. Reactions with volume change viii. Reactor types ix.
Homogeneous and heterogeneous reactions x. Catalysis.
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Suggested Books:
Levenspiel Octave, Chemical Reaction Engineering, 2nd Ed. 1999,
John Willey & Sons Inc.
Smith J.M., Chemical Engineering Kinetic, 2001, McGraw Hill Book
Co.
Fogler H. Scott, Elements of Chemical Reaction Engineering, 2nd
Ed., 2001, Prentice Hall
E Bruce Naumen, Chemical Reactor Design, Optimization and Scale
up, 2002, McGraw Hill.
4. PLANT DESIGN AND OPERATION 25%
i. Economic Consideration
Equipment-cost correlations /economic calculations
Operating costs
Time value of money.
ii. Design and Operation
Process equipment design
Process flow sheet development
Design optimization
Operating manuals (e.g., startup, shutdown, maintenance)
Equipment testing, troubleshooting, and analysis.
iii. Safety
Emergency venting devices (e.g., safety valves, blowout
walls)
Performance of scheduled audits (e.g., testing safety valves,
checking rupture, disks)
Flares and vents
Plant layout considerations (e.g., equipment arrangement, pipe
racks, and layouts)
Fire protection
Emergency ingress and egress
Process hazard analysis.
iv. Environmental
Evaluation and permitting of gas discharges and liquid
discharges
Solid waste management (non-hazardous and hazardous)
Industrial hygiene (e.g., MSDS, TLV, noise control, ventilation,
personal protective equipment)
Pollution prevention.
Suggested Books:
Peters Max S., Timmerhaus Klaus D., Plant Design and Economics
for Chemical Engineers, 4th Ed., 1991, McGraw Hill Inc.
Ludwig Ernest E., Applied Process Design for Chemical and
Petrochemical Plants, Voll 1,2 & 3, 3rd Ed.2002, Gulf
Publishing Company.
Walas Stanley M., Chemical Process Equipment Selection and
Design, 1999, Butterworth Heinemann.
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Coulson J.M, and Richardson, Chemical Engineering, 1999, Vol VI,
Butterworth Heinemann.
Wells G. L. Rose L.M., The art of Chemical Process Design, 1986.
Elsevier.
Smith Robin, Chemical Process Design, 1995, McGraw Hill Inc.
Backhurst & Harker, Chemical Process Design, John
Willey.
Evans, Handbook of Chemical Equipment Design PART-III-B: (To be
selected only one opted area)
This part aims to assess the depth of Chemical Engineering. This
part comprises of 20 multiple choice questions for 1.5 hours and
only one opted area of practice will be attempted by the respective
candidates. 1. PROCESS SYNTHESIS, DESIGN AND OPTIMIZATION
i. Process Design
a. Fundamentals
Process design steps ,primary considerations in process
design
Development of base-case design.
b. Detailed
Equipment sizing, separation equipments design
Pumps, compressors, and expanders, optimal design of batch
processes.
ii. Process Synthesis
Objectives of process synthesis, reactor network synthesis
Synthesis of separation trains, sequencing of columns.
iii. Process Flow Diagram: (tool for synthesis and
optimization)
Reactor section , separator section, feed preparation sections
for reactor and separation sections, important process control
loops
Process simulation, instrument for process synthesis
What is a process simulator?, simulator input data
Selection of chemical components, thermodynamic models, feed
stream
properties, equipment parameters and convergence criteria
Case Studies.
iv. Analysis of a Process
The Input-Output Structure of a Process Flow Diagram,The Block
Flow
Process Diagram
Equipment classification as function Block in PFD.
Interpretations of a Process Flow Diagram
Tracing chemicals in PFD, Tracing Primary Paths Taken by
Chemicals in
Process
Recycle and Bypass Streams, Inert Chemicals path.
Reactor Performance
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Reactor-Separator-Recycle Network
v. Process Optimization
Starting point for optimization, selection of objective
function
Key decision variables, heat and power integration
Topological optimization
Eradication of hazardous waste, equipment rearrangement
Alternative separation schemes and reactor configurations
Enhancement in heat integration
Parametric optimization
Single variable optimization, two variable optimization
Process flexibility and the sensitivity of the optimum.
Suggested Books:
Richard Turton, Richard C. Bailie at el., Analysis, Synthesis,
and Design of Chemical Processes, 3rd Ed., 2008, Prentice Hall ,
PIR,
Ian C Kemp, Pinch, Analysis and Process Integration, Elsevier
Publishers, 2007
Kai Sundmacher, Integrated Chemical Processes, WILEY-VCH Verlag
GmbH & Co. KGaA, Weinheim, 2005,
2. OPERATION AND PRODUCTION ENGINEERING
i. Introduction to Production and Operations Management
Production and operations management
Basic functions of business organization
Designing and operating production systems
Differentiating features of predictions systems
Analysis of tradeoff system approach establishing priorities,
pareto phenomena
Recent trends in production and operations management.
ii. Productivity strategy and competitiveness
Concept and Types of Productivity
Factors affecting productivity
How productivity can be improved?
How to formulate strategy?
Order qualifiers, order wining, mission, mission statement, aim,
tactics, vision
In how many ways organization compete with one another?
Quality and time based strategies.
iii. Forecasting
Features of forecasting
Elements of a good forecasting
Steps involved in forecasting
Approaches to forecasting
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Qualitative techniques (judgment and opinion, delphi method,
customer survey)
Quantitative techniques (nave, moving average, weighted average,
exponential smoothing, trend adjusted exponential smoothing
Techniques for seasonality
Accuracy and control of forecasting
Summarizing forecasting accuracy
Controlling the forecasting
Choosing forecasting techniques.
iv. Decision Making
Decision process
causes of poor decisions
decision making environment
decision theory
decision making model
Expected value of perfect information
Sensitivity analysis.
v. Product and Service Design
Reasons for product and service design
Needs for product and service design
Product liability
Research and development
Product life cycle
Standardization
manufacturing design
Robust design
Concurrent design (taguchi approach)
Concurrent engineering
Computer Aided Design (CAD)
Service design
Difference between product and service design
Quality function deployment.
vi. Reliability
Improving reliability
Quantifying reliability
Models for calculating reliabilities.
vii. Process Selection and Capability Planning
Process selection
Make or buy
types of operation
Continuous and semi-continuous processing
Intermittent processing
Automation
Capacity planning
Importance of capacity decisions
Defining and measuring capacity
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Determination of effective capacity
Determining capacity requirements
Cost volume analysis.
viii. Facilities Layout
Facilities layout
Basics layout types
Product layout
Process layouts
Fixed position layouts
Combination layouts
Cellular layouts
Cellular manufacturing
Group technology
Flexible manufacturing
Other service layouts
Warehouse and storage layouts
Retail layouts
Office layouts
Designing product layouts line balancing
Designing process layouts.
ix. Project Management
Pros and cons of project management
Pert and CPM, difference between pert and CPM
Slack time
Critical time
Gantt charts and network charts
Project management software
Time cost tradeoff.
Suggested Books:
William J. Stevenson, Production / Operations Management, 6th
Ed., 1999, ISBN 0-07-366112-0.
William J. Stevenson, Operations Management, 8th Ed., 2005, ISBN
0-07-111218-9.
Jay Heizer and Barry Render,Production and Operations
Management: Strategies and Tactics.
Richard J. Tersine, Production / Operations Management:
Concepts, Structure and Analysis.
3. UTILITIES AND SERVICES ENGINEERING
i. Offsite/ Utilities & Support Services
Raw water treatment
Seawater treatment (desalination)
Boiler feed water treatment (demineralization, softening,
reverse osmosis, deaeration)
Steam generation and distribution
Condensate recovery and treatment (polishing, deaeration,
deoiling)
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Other water systems (chilled water, electronic grade, Water For
Injection (WFI), purified water)
Cold/hot oil belt systems
Water reuse/recycle.
ii. Plant Operations Support Processes / Services &
Offsites
Safety relief systems (flares)
Blow down (open, closed)
Fuel systems (oil, gas, solids)
Storage (tankage, tank, )
Loading and unloading facilities
Blending (in-line, in-tank)
Shipping (jetty, rail, road)
Air supply (plant and instrument air storage, drying, delivery,
distribution)
Inert gas supply
Cooling water systems (open, closed, reduced plume)
Firewater system
Potable water system
Refrigerant systems
Materials handling
Sulfur storage, handling
Flushing oil systems
Chemical handling and distribution
Slop systems
Hot oil system
Power generation system
Waste heat recovery & power generation
Chemical injection system
Waste disposal
Produced water disposal system / treatment.
Suggested Books:
Jack Broughton, Introduction to Design, Operation and
Maintenance,
Charles C. Patton, Applied Water Technology, 2nd Ed., 1995,
ISBN: 10: 9998157234.
Eastop, Allan McConkey, Applied Thermodynamics for Engineering
Technologists, 1997, Harlow : Longman, ISBN: 0582091934
A.H. Hewllet Thermodynamics Applied for Heat engines. 4.
ENVIRONMENT AND PROCESS SAFETY ENGINEERING
i. Chemical process safety fundamentals
ii. Toxicology and industrial hygiene, toxic and flammable
releases and dispersion models, process hazards identification and
analysis techniques, toxic chemicals and ground water pollution
iii. Process risk assessment and management, process safety
management systems and standards, accident investigation and
reporting
iv. Industrial personal protection equipment, emergency planning
and response
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v. International conventions for safe use of chemicals, clean
development mechanism
vi. Solid, water, air and noise pollution and their control
vii. Global environmental problems, ecosystem and sustainable
development
viii. Environmental impact assessment techniques
ix. Converting refuse to resources, environment friendly green
energy policy, risk and economics of pollution.
Suggested Books:
CCPS, Guidelines for Chemical Process Quantitative Risk
analysis, 1989, AIChE, New York, Vol 32, 1989.
Crowl, D.A. and Louvar, J.F., Chemical Process Safety:
Fundamentals with applications, 2nd Ed., Prentice Hall, Englewood
Cliffs, New Jersey, 2001.
Jonthan, T., Occupational safety and health management, 2nd Ed.,
2006, Mcgraw Hill.
Davis, M.L. and Cornwell, D.A., Introduction to Environmental
Engineering, 3rd Ed., 1998, McGraw-Hill, ISBN: 0-07-015918-1.
Nebel, B.J., Environmental Sceince: The way the world works, 3rd
Ed. 1990, Prentice Hall.
5. INSTRUMENTATION AND CONTROL ENGINEERING
i. Principles of Measurement
Accuracy, Precision/repeatability, error, tolerance, range or
span, bias, linearity, sensitivity of measurement, sensitivity to
disturbance, hysteresis, dead space, threshold resolution, noise
and filtering
Units for Measurement of Physical Variables: temperature, level,
flow, pressure, force, length, acceleration, velocity, frequency,
time.
ii. Process Dynamics, Modeling and control
Process variables, first order and second order systems, closed
loop control systems, feedback, feed forward, cascade, override
control proportional
Proportional Integrative (PI)
Proportional Integrative Differential (PID) controls
Time constant, transfer functions
Steady state design and dynamic controllability.
iii. Control Systems
Pneumatic control systems
Digital control systems
Digital data acquisition systems
Analog and digital detectors converters
Transducers field wiring
Sensors and transducers
Hardware and software for modern control system.
iv.Process Simulation
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Use of computers and Applications of process simulation.
v. Diagrams used in process instrumentation
Use of software for drawing a process instrumentation
diagram.
vi. Valves and their Types, selection criteria for valves
xi. Temperature, Pressure, level and Flow measuring devices
Design, selection criteria, types, calibration, accuracy,
sensitivity.
xii. Case Study, Designing of a control system for a process
Suggested Books:
Coughner D R and Koppel C.B, Process System Analysis and
Control, McGraw Hill, 1991.
William L. Luyben, Process Modeling, Simulation and Control for
Chemical Engineers, 2nd Ed., 1996, McGraw Hill Publishers.
Carlos A.Smith, Armando B.C., Principles and Practice of
Automatic Process Control, 3rd Ed., 2006, John Wiley and Sons.
ISA - International Society of Automation,
http://www.isa.org
Tony R. Kuphaldt, Lessons In Industrial Instrumentation,
Creative Commons, 2009.
Marlin T.E., Process Control, 2nd Ed., Mc Graw Hill, 2000.
Ogunnaike, B.A. et al, Process Dynamics Modelling and Control,
Oxford University Press, 1997.
6. THERMAL HYDRAULICS
i. Two-Phase Flow
Two phase flow regimes
Two-phase flow regimes in adiabatic pipe flow, vertical,
cocurrent, upward flow, cocurrent horizontal flow
Flow regime maps for pipe flow
Two-phase flow regimes in vertical rod bundles
Two-phase flow models
Flow-area averaging
One-Dimensional Homogeneous-Equilibrium Model: single-component
fluid
One-Dimensional Homogeneous-Equilibrium Model: two-component
mixture
One-Dimensional Separated Flow Model: single-component fluid
One-Dimensional Separated-Flow Model: two-component fluid
The drift flux model
Pressure drop in two-phase flow
Two-phase frictional pressure drop in homogeneous flow and the
concept of a two-phase multiplier
Empirical two-phase frictional pressure drop methods.
ii. Boiling Heat Transfer
Pool boiling, the pool boiling curve, heat transfer mechanisms
in nucleate boiling, nucleate boiling correlations
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The hydrodynamic theory of boiling and critical heat flux, film
boiling, transition boiling, flow boiling, forced-flow boiling
regimes, flow boiling curves
Flow patterns and temperature variation in subcooled boiling,
onset of nucleate boiling, empirical correlations for the onset of
significant void
Hydrodynamics of subcooled flow boiling, pressure drop in
subcooled flow boiling , fully developed subcooled flow boiling
heat transfer correlations
Characteristics of saturated flow boiling, saturated flow
boiling heat transfer correlations
Two-phase flow instability, static instabilities, dynamic
instabilities
Critical Heat Flux (CHF) and Post-CHF heat transfer in flow
boiling, CHF mechanisms
Experiments and parametric trends, correlations for upward flow
in vertical channels, correlations for subcooled upward flow of
water in vertical channels
Models for DNB and dryout
CHF in inclined and horizontal channels
Post-Critical Heat Flux heat transfer 399.
iii. Choked Flow
Physics of choking
Velocity of sound in single-phase fluids
Critical discharge rate in single-phase flow
Choking in homogeneous two-phase flow
Choking in two-phase flow with interphase slip
Critical two-phase flow models
The homogeneous equilibrium isentropic model
Critical flow model of moody
Critical flow model of henry and fauski.
Suggested Books:
Thome Collier, John R Thome, John G Collier, Boiling and
Condensation, 3rd Ed., Oxford University Press, USA, 1996.
Todreas and Kaazmi, Nuclear Systems, Vol 1 & 2, Taylor and
Francis Grouch 1989.
S. Mostafa Ghiaasian, Two-Phase Flow, boiling and Condensation
in Conventional and Miniature Systems, Cambridge University Press
2008.
7. POLYMER ENGINEERING
i. Polymer, classification and properties, application of thermo
plastic ii. Polymerization techniques iii. Role of additives &
fillers with their applications iv. Thermal behavior and
degradation of polymers v. Major polymer processing methods vi.
Rheological properties vii. Analytical, physical, mechanical and
thermal testing viii. Fundamentals of mould & die design.
-
Suggested Books
Fried Joel R. Polymer Science and Technology, 2000, Prentice
Hall.
Stanley Middlean, Fundmentals of Polymer Engineering, 3rd Ed.,
1996
Tim A. Ossworld, Georg Menges, Hanser, Material Science of
Polymer for Engineering, 2003.
I.M. Ward & D.W. Hadley, Wiley, An Introduction to the
Mechanical Properties of Solid Polymer, 3rd Ed., 1998.
8. BIOCHEMICAL ENGINEERING
i. Basic microbiology, biochemistry and biochemical
engineering
ii. Enzymes kinetics and immobilization techniques, and their
industrial applications
iii. Unit operation for bioprocesses, biochemical unit
processes
iv. Design, operation and control of bio reactors, along with
recovery and purification of products
v. Application of bioprocesses in pharmaceutical, food industry
and waste treatment
vi. Economic analysis of biological processes.
Suggested Books:
Shigeo Katoh, Fumitake Yoshida, quot, Biochemical Engineering: A
text book for engineers, chemists and biologists, Wiley-VCH, 2009,
ISBN: 3527325360.
Schuler, M.L.and Kargi, F., Bioprocess Engineering: Basic
Concepts, 2nd Ed.,Prentice Hall, New York, ISBN: 0-13-081908-5.
Lee, J. M., Biochemical Engineering, 1992, Prentice Hall.
Blanch, H. W. and Clark D. S., Biochemical Engineering, 2nd Ed.,
1996.
Cutlip, M. B. and Shacham, M., Problem Solving in Chemical and
Biochemical Engineering with Polymath, Excel and MatLab, 2nd Ed.,
Prentice Hall.
9. ENERGY ENGINEERING
i. Energy Proem (Trends & Classifications)
Energy supply and demand analysis
Types and forms of energy
Worldwide/countrywide energy scenario
Futuristic sustainable energy approaches
Statistical energy demand speculation.
ii. Non-renewable Energy Sources
Fossil fuels, generation, processing and consumption of fossil
fuels
Value addition by chemical and physical treatment of fossil
fuels
Isomerization, cracking, reforming, vis-breaking and
hydrogenation treatment
Fuel conversion, gasification, carbonization, liquefaction and
fuel pulverization
-
Nuclear processes and power plants
Combustion & flammability.
iii. Renewable/Sustainable Energy Sources
Alternative energy resources
Power systems operating on wind energy, solar energy, tidal
energy
Pressure retarded osmosis
Water (hydel) energy
Geothermal energy
Bio-chemical energy (biomass).
iv.Energy systems and Industry
Optimization of energy systems
Audit and conservation of energy in chemical and process
industries
Energy resource utilization
Simulation and hazard analysis of energy systems
Operational troubleshooting
Thermal power plants
Turbines / expanders
Nuclear power plants.
Suggested Books:
Boyle, G., Everett, B., and Ramage, J.,Energy Systems &
Sustainability, First Edition, Oxford University Press, 2003.
Hinrichs, R. A., and Kleinbach, M. H., Energy: Its Use and the
Environment, 4th Ed., Brooks, 2005.
Vanek, F., and Albright, L. D., Energy Systems Engineering
Evaluation and Implementation, 1st Ed., McGraw Hill Professional,
2008.
Capehart, B. L., Encyclopedia of Energy Engineering and
Technology, 1st Ed., CRC Press, 2007.
10. SEPARATION PROCESS ENGINEERING
i. Separation Processes
Difference between conventional and novel separation
processes
Advantages and classification of novel separation processes
Analysis and design of following novel separation processes
Reverse osmosis
Ultra-filtration
Dialysis / electro-dialysis / donnan dialysis
Liquid membranes / polymeric membranes
Foam fractionation
Adsorption / parametric pumping
Freezing processes.
ii. Optimization of Separation Processes
Application of optimization techniques to separation process
engineering
linear programming for optimization of multi-component
distillation columns
Dynamic optimization for separation systems in transient
state.
-
iii. Separation Processes in Industry
Operational procedures regarding separation processes
Hazard Analysis
Safety and Environmental Issues
Effect of various process control parameters (temperature, flow,
level, pressure, composition) on separation processes
Troubleshooting and Operational problems.
Suggested Books:
Rousseau, R. W., Handbook of Separation Process Technology, 1st
Ed., Wiley Inter-Science Publication, 1987.
Khoury, F. M., Multistage Separation Processes, 3rd Ed., CRC
Press, 2005.
Scott, K., Handbook of Industrial Membranes, 2nd Ed., Elsevier
Science & Technology Books, 1999.
Sinaiski, E. G. and Lapiga E. J., Separation of Multiphase,
Multi-component Systems 1st Ed., Wiley VCH, 2007.
Tarleton, E. S. and Wakeman, R. J., Solid Liquid Separation:
Equipment Selection and Process Design, 1st Ed., Elsevier,
2007.
Petlyuk, E. B., Distillation Theory and Its Application to
Optimal Design of Separation Units, 1st Ed., Cambridge University
Press, 2004.
11. CORROSION ENGINEERING
i. Corrosion and Its Control (Theory and Practice)
Types of corrosion
Factors influencing corrosion
High-temperature attack
Combating corrosion
Corrosion-testing methods
Economics in materials Selection.
ii. Selection of Optimum Material of Construction
Mechanical properties and Design considerations
Structural Design Considerations
Cost of Materials
Corrosion resistance/ corrosion protection.
iii. Properties of Materials
Materials Standards and Specifications
Alloys, inorganic non-metallic, ceramics, organic non- metallic
, polymers, plastic materials, thermoplastics, thermosetting
plastics, rubber and elastomers, asphalt, carbon, graphite,
wood.
iv. High and Low Temperature Materials
Low-Temperature Metals and alloys,
High-Temperature Materials and alloys,
Refractories and insulation.
-
Suggested Books:
Robert H. Perry, Don W. Green, Chemical Engineers Handbook, 7th
Ed.,
William D. Callister, Introduction to Material Science, 5th
Ed.,
Prof (R) Dr. Ijaz Hussain Khan, Corrosion Technology, Vol 1 and
Vol 2, Institute of Chemical Engg. & Technology, PU, LHR